Apparatus for controlling thickness of cast anode copper and the like

ABSTRACT

A vertically movable gauge, aboard a lift and carrying sensing means at its lower end, is adapted to be lowered in latched conjunction with the lift from an elevated clearance position above a mold of a casting wheel to bring the sensing means into physical contact with the bottom of the mold; it is further adapted to be then unlatched from the lift and individually retracted from such contact position a distance predetermined by the desired thickness of the anode, while the lift is being held by a brake to preserve the starting position which varies from mold to mold. When the molten metal poured into the mold rises to the level of the retracted sensing means, it causes a signaling and/or control system to be actuated. Pouring is immediately stopped, manually or automatically. The brake is then released and the lift raised to its original position, meanwhile picking up the retracted gauge device. The gauge is driven down to its original extended position relative to the lift and is relatched to the lift at the original wheel-clearance level, which permits rotation of the casting wheel to remove the full mold and to position an empty mold. The apparatus is preferably pneumatically or hydraulically operated in conjunction with a fluidic control circuit and electrical sensing and control circuitry.

United States Patent [54] APPARATUS FOR CONTROLLING THICKNESS OF CAST ANODE COPPER AND THE LIKE 8 Claims, 8 Drawing Figs.

[52] US. Cl 340/244, 33/ 126.7 A [51] int. Cl G0lf 23/04 [50] Field of Search 340/244;

[56] References Cited UNITED STATES PATENTS 3,054,188 9/1962 Cupido et al. 33/l26.7 A 3,494,191 2/1970 Cawley et al. 73/290 Primary Examiner.lohn W. Caldwell Assistant ExaminerDaniel Myer Attorneys-John l... Sniado, Mallinckrodt and Mallinckrodt, P.

H. Mallinckrodt and Philip A. Mallinckrodt ABSTRACT: A vertically movable gauge, aboard a lift and carrying sensing means at its lower end, is adapted to be lowered in latched conjunction with the lift from an elevated clearance position above a mold of a casting wheel to bring the sensing means into physical contact with the bottom of the mold; it is further adapted to be then unlatched from the lift and individually retracted from such contact position a distance predetermined by the desired thickness of the anode, while the lift is being held by a brake to preserve the starting position which varies from mold to mold. When the molten metal poured into the mold rises to the level of the retracted sensing means, it causes a signaling and/or control system to be actuated. Pouring is immediately stopped, manually or automatically. The brake is then released and the lift raised to its original position, meanwhile picking up the retracted gauge device. The gauge is driven down to its original extended position relative to the lift and is relatched to the lift at the original wheel-clearance level, which permits rotation of the casting wheel to remove the full mold and to position an empty mold.

The apparatus is preferably pneumatically or hydraulically operated in conjunction with a fluidic control circuit and electrical sensing and control circuitry.

PATENTED SEP28|97l 3,609.738

sums or 3 uov AC. IN CONTROL BOX- IN HOUSING a3 INVENTOR. HENRY w PHANZ AT TORNE YS APPARATUS FOR CONTROLLING THICKNESS OF CAST ANODE COPPER AND THE LIKE BACKGROUND OF THE INVENTION Field The invention is in the field of apparatus for the control of the level to which a mold is filled and is concerned particularly with such apparatus as is adapted to control the levels to which a plurality of molds are successively filled with a cast material, such as molten metallic copper.

State of the Art The pouring of molten copper in the anode molds of a casting wheel, the bottoms of which molds vary in level, has been commonly a matter of manual control exercised by the wheel man from a somewhat remote location in the control cab on the basis of visual observation of an index mark in the anode mold. Often the view is obscured by intervening clouds of water vapor, mold wash spray, etc. Problems of high humidity, high temperature, and vibration, as well as the peculiar requirements, have made it impractical to adapt conventional liquid level control systems to this task. Although it is not new in general to sense the levels of molten metal successively poured into a plurality of molds and to control the pour accordingly, see for example Dressel US. Pat. No. 3,353,586, there were problems of reliability, adaptation to particular situations, etc. that were not solved prior to the present invention.

same thickness. It was a further objective to provide a fluidic control system as a part of the apparatus.

SUMMARY OF THE INVENTION For accomplishing the objectives of the invention, a vertically movable gauge, preferably in the form of an indexing rod, depends rigidly from a fluid-actuated power device carried by a lift which is adapted to descend and ascend, preferably by fluid actuation, from a fixed position above a mold station. For each mold-filling cycle, the lift is caused to descend in latched relationship with the gauge until such gauge bottoms in the mold, whereupon the gauge is unlatched from the lift and raised by its power device a predetermined distance equal to the desired thickness of the casting. A positive-acting, grab brake is provided to hold the lift in fixed position during the raising of the gauge and the pouring of material into the mold cavity, so that the variable starting position of the gauge will be preserved until the pour is completed. Sensing means, preferably in the form of spaced electrodes flush with the lower end of the indexing rod, serve to actuate a pour-control circuit or a signal for the wheel man when the material reaches the level of such sensing means. The brake is then released and the lift raised. As the lift travels upwardly, it picks up the gauge and assumes its original position. The gauge is extended downwardly from its retracted to its original position relative to the lift and is relatched to the lift in preparation for the next cycle. As such it is high enough above mold level to provide clearance for mold movement along the horizontal.

A fluidic control circuit is advantageously provided for operating the several components, namely, the lift, the latching mechanism, the gauge device, and the brake in timed sequence. The sensing means and the controls for the fluidic circuit are advantageously electrical.

THE DRAWINGS The particular apparatus and control system shown in the accompanying drawings represent the best mode presently contemplated of carrying out the invention.

In the drawings:

FIG. 1 represents a fragmentary top plan view of a typical copper anode casting wheel and pouring spout for filling the molds carried by the casting wheel, the apparatus of the invention-being operatively mounted relative to both casting wheel and pouring spout;

FIG. 2, a fragmentary vertical section taken on the line 2-2 of FIG. 1, illustrating the apparatus of the-invention in side elevation with indexing rod and molten-metal-sensing electrodes fully retracted into a position which clears the casting wheel;

FIG. 3, a vertical section taken on the line 3-3 of FIG. 2 to show working parts of the apparatus of the invention, intermediate the base portions of the mounting structure being broken out for convenience of illustration;

FIG. 4, a corresponding view showing the indexing rod and sensing electrodes bottomed in an anode mold carried by the casting wheel;

FIG. 5, a view corresponding to the lower portion of FIG. 4, but showing the gauge unlatched from the lift platform and retracted a predetermined distance to place the sensing electrodes at the exact level to which the particular anode mold is to be filled;

FIG. 6, a fragmentary view in axial vertical section through the brake mechanism and directed only to that structure comprehended by the broken line 6 in FIG. 5;

FIG. 7, a flow sheet of the fluidic control system advantageously employed with the apparatus of the foregoing figures; and

FIG. 8, a wiring diagram detailing the electrical circuitry employed with the fluidic control system of FIG. 7.

DETAILED DESCRIPTION OF ILLUSTRATED EMBODIMENT The apparatus illustrated is designed especially for use in the casting of molten copper by way of a pouring spout 10 into the anode molds ll of a conventional casting wheel 12. The working components of the apparatus are protectively encased within a housing 13 that is advantageously liquid cooled by means of a coolant, such as water, circulated by way of hoses l4 and 15 through the interiors 13a of hollow walls of the housing.

As shown, the housing 13 is mounted at the end of a bracket 16 which extends from a post 17 fixed to one of the usual ladle-supporting columns 18 by means of yokes l9.

Secured within the housing 13 is a stationary platform 20 for supporting the lift means and the brake means. Mounted on the platform 20 is a fluid-actuated piston and cylinder power device 21, whose piston rod 21a extends through a slideway hole in such platform to connection with a lift platform 22 that rides up and down on vertical guide rods 23 depending rigidly from platform 20. Such platform 22 and guide rods 23 provide the lift means.

Also mounted on platform 20 is a fluid-actuated piston and cylinder power device 24, whose piston rod 24a extends through a slideway hole in such platform to connection with a brake for the lift means. Mounted aboard lift platform 22 is a bracket 25 having a platform 25a on which is mounted a fluidactuated piston and cylinder power device 26, of short stroke relative to the lift power device 21. Its piston rod 26a extends through a slideway hole in such platform to connection with a gauging platform 27 that rides up and down on vertical guide rods 28 depending rigidly from platform 25a.

Depending from the gauging platform 27, as part of the gauging means, is a gauge in the form of a rigid indexing rod 29 that projects through an opening l3b in the bottom of the housing. Secured to the projection portion of the indexing rod by a collar 30, so as to be flush with the lower end of such indexing rod, are spaced electrodes 31 and 32 having electrical leads 31a and 320 that extend upwardly into the housing.

Latching means are provided between the lift means and the gauging means, so the latter can be lowered with the former from mold-clearance height, FIG. 3, by reason of the relatively long stroke of the power device 21 until indexing rod 29 and electrodes 31 and 32 bottom on a mold 11, H6. 4, and so that the gauging means can then be released for independent upward movement a predetermined shorter distance to place the electrodes at the desired molten-metal-sensing height, FIG. 5, for controlling the quantity of pour and, thus, the thickness of the cast anode. As shown, the latching means comprises a latchbolt 33, carried by the lift platform 22, and a latch keeper 34 carried by the gauging platform 27. Bolt 33 constitutes the piston rod of a fluid-actuated piston and cylinder power device 35 secured to the underside of lift platform 22.

The latching means also includes catch means for enabling the lift means to pick up the gauging means in the retracted sensing position thereof as such lift means is returned to its original mold-clearing position. As illustrated, such catch means advantageously comprise abutment catch members in the form of a portion 27a of the gauging platform overlapping a portion 220 of the lift platform.

The brake is provided to hold lift platform 22 precisely in its gauged positions, FIGS. 4 and 5, during the raising of indexing rod 29 and electrodes 31 and 32 to the sensing position. It is of grab type, so it will respond immediately and hold positively. As illustrated, H0. 6, it is of conventional construction comprising a series of hard steel washers 36 packed in an inwardly open, annular container 37 along with a spring 38. Piston rod 21a of lift power device 21 extends through the otherwise open center of this grab package and is tightly held whenever the package is forcibly tilted to cause the washers to bind against the rod. Tilting is accomplished when fluid under pressure is introduced into the upper end of the cylinder of power device 24 to force piston rod 24a downwardly. The lower end of such piston rod is fastened to a lever arm 39 that extends from one side of the container 37 and rides up and down a guide post 40 against a reaction spring 41 that insures almost instantaneous brake release. An oppositely extending lever arm 42 has its end fulcrumed in a V-recess 43a of a block 43 that is adjustably secured to a threaded mounting post 44 and is fixed in adjusted position by a set screw 45.

lt is a feature of the invention that the apparatus so far described is adapted for controlled operation by means of fluidic control circuitry that is, in turn, governed by preferably electrical sensing circuitry.

As shown in FIG. 7, the fluidic circuitry includes the double acting, air cylinder, power devices 21, 24, 26, and 35 and two conventional air-pilot-operated, four-way valves 50 and 51. Compressed and filtered air, e.g. at 28 p.s.i.g., is supplied to the valves 50 and 51 from any suitable source (not shown) through a supply line 52 and respective branch lines 52a and passes to one or the other side of the pistons of the respective air cylinders by fluidic tubing 21b, 24b, 26b, and 35a respectively, as determined by the positions of the spools of the respective valves 50 and 51.

In order to control operation of the system, air from the main supply line 52 is passed through a branch line 53 and through a variable resistor valve 54, which reduces its pressure, e.g. to 7 p.s.i.g., and is directed to three or/nor gates 55, 56, and 57. These gates serve to supply air signals for positioning the spools of valves 50 and 51 and for actuating an airoperated electric switch 58. Two fluidic proximity sensors 59 and 60, supplied with air through suitable flow lines, as indicated, serve as triggering means for the fluidic or/nor gates 55 and 56, respectively, that control timed sequence of operation of the valves 50 and 51. A third proximity sensor 61 actuates the air-operated, electric switch. A solenoid-operated, air valve 62, controlled either manually or automatically, also exercises control over the spool of valve 50. Another solenoidoperated, air valve 63 is actuated by the electrodes 31 and 32 when the molten copper cast into the mold is at the correct level and makes electrical contact with such electrodes. Conventional fluidic delay devices, i.e. capacitors 21c, 24c, 26c, 35b and 57a and resistor 24d, are also used in the timing of sequential operation of the several power devices and the gate 57, respectively.

The associated electronic circuit of FIG. 8 is typical of the type of electronic circuit that can be employed in conjunction with the fluidic circuitry of FIG. 7. It includes a stepdown transformer 64 as a safety measure to provide low voltage, e.g. 6 volts, current for the solenoid coils 62a and 630, FIG. 8, of solenoid-operated, air valves 62 and 63, respectively. The same low voltage current is used also to energize indicating light 65, 66, and 67, FIG. 8, mounted in a suitable control box. Also mounted in the control box are normally open, pushbutton, electric switches 68 and 69.

The control box is placed at a convenient location, usually within easy reach of the casting wheel operator. As shown, it is energized from a volt source of AC electrical power. Suitable electrical connections are provided in both the control box and the housing 13 and a length of electrical cable having an appropriate number of conductors is run from the control box to the housing 13. Electrical contacts 580 and 58b for an air-operated, electrical, double pole switch 58 and electrical contact 704 for a companion air-operated, electrical, single-pole switch 70 are mounted within housing 13.

The functions and the timed sequence of the entire system can be best illustrated by describing a complete cycle of the operation of the apparatus.

In operation, starting switch 68 is actuated, either manually, or automatically by means of a signal from the casting wheel mechanism, to energize solenoid coil 62a of air valve 62, which opens thevalve and causes the spool of valve 50 to shift. This, in turn, causes the piston of power cylinder 21 and lift platform 22 to be driven downwardly. It should be noted that a fixed, air bleed resistor 71 in the fluidic circuitry relieves pressure from the right-hand pilot port of valve 50 after the pilot has been actuated and permits the spool of such valve 50 to move to the right when the left-hand port is pressurized.

Since the gauging platform 27 is already latched to the lift by the latchbolt piston 33 of power cylinder 35, it moves downwardly with the lift. Downward movement continues until the lower end of indexing rod 29 physically contacts the bottom of the mold cavity, which halts the downward movement. I

Right after the lift platform 22 has started its downward movement, proximity sensor 59 is uncovered. This removes the signal from or/nor gate 55 and causes venting of gate output to atmosphere, which relieves the right-hand pilot pressure on valve 51.

Capacitor 24c and resistor 24d in branch line 24b provide pressure delay for power cylinder 24. When the delayed pressure reaches the rear of power cylinder 24, indexing rod 29 having meanwhile bottomed" in the mold, the piston rod 24a of power cylinder 24 is driven outwardly which actuates brake lever arm 37 nd sets the brake that prevents further movement of indexing rod 29.

Immediately after piston rod 24a has so moved outwardly to set the brake, proximity sensor 60 is covered. This switches or/nor gate 56 to actuate the left-hand pilot inlet of valve 51, thus permitting air to enter the front of power cylinder 35 for retracting latchbolt 33. A pressure-delay branch through capacitor 26c runs to the bottom of power cylinder 26 and retracts gauging platform 27 and indexing rod 29 a predetermined distance established in accordance with the desired thickness of the casting.

As latch bolt 33 is retracted, proximity sensor 61 is uncovered. This vents signal air to relieve air pressure on airoperated electric switch 58, which causes it to close with respect to its contact 58a and to thereby complete a circuit which powers pour" light 67 in the control box. Switch 58 is normally closed with respect to its contact 58b which completes a circuit powering standby" light 66. Thus, such standby light is shut off when switch 58 is thrown from its normal position.

The operator then proceeds to fill the mold with molten copper by way of pouring spout 10. When the level of the molten copper rises to make contact with electrodes 31 and 32, an electric circuit is completed which energizes the solenoid coil 63a of air valve 63, causing a fluidic signal to actuate or/nor gate 57.

Or/nor gate 57, when so actuated, supplies air pressure to the left-hand pilot of valve 50, and, through delay capacitor 57c, to air-operated electric switch 70 to close it, thereby completing a circuit which powers "stop" light 65. The switch is held closed momentarily by the delay action of capacitor 57b thereby holding the stop" light lighted for a few seconds of time.

The pressure on the left-hand pilot of valve 50 causes the spool of such valve to shift permitting air to enter the bottom of cylinder 24 directly, thus retracting rod 24a and releasing the grab of brake washers 36 on piston rod 26c. The delay capacitor 21b then transfers air to the bottom of power cylinder 21 to retract piston rod 21a and raise lift platform 22 for withdrawing indexing rod 29 and electrodes 31 and 32 from the mold cavity in preparation for another cycle with respect to the next mold in the casting wheel 12.

When lift platform 22 is fully raised, proximity sensor 59 is covered and a fluidic signal is sent to or/nor gate 55, which shifts and applies air pressure to the right-hand pilot of valve 51. This pressure causes the spool of valve 51 to shift, permitting air to enter the top of power cylinder 26, thereby driving piston rod 26a and gauging platform 27 downwardly. Air from valve 51 enters the right-hand end of power cylinder 35 through delay capacitor 35b and drives latch pin 33 into latching engagement with its keeper 34. This movement of latch pin 33 covers proximity sensor 61 and sends a fluidic signal, which causes air-operated electric switch 58 to close with respect to its contact 58b, thereby completing the electric circuit that powers standby" light 66.

Whereas the invention is here illustrated and described in detail with respect to a form thereof presently contemplated as the best mode of carrying out the invention, it should be realized that various changes therein and other specific forms of the invention are also possible.

lclaim:

1. Apparatus for controlling the thickness of castings poured into successive molds, comprising means for sensing level of cast material;

lift means;

gauging means carried by the lift means and carrying the sensing means in operative position, said gauging means being vertically movable independently of the lift means; means for latching the gauging means to the lift means for movement therewith to lower the sensing means to moldbottom level and to raise the sensing means above mold height;

brake means for holding the lift means in a gauged position while the gauging means is being independently raised to a predetermined sensing height above the bottom of a particular mold;

and means for actuating the lift means, the latch means, the

gauging means, and the brake means, respectively.

2. Apparatus in accordance with claim 1, wherein the gauging means includes a rigid, depending, indexing rod and carries a latch keeper that forms part of the latch means, the sensing means being flush with the lower end of said indexing rod; and wherein the latch means also includes a latchbolt carried by the lift means and adapted to be thrown into and to be withdrawn from said keeper.

3. Apparatus in accordance with claim 2, wherein the latch means includes abutment catch members on the lift means and the gauging means, respectively, for mutual engagement to raise the sensing means above mold height independently of the latchbolt and keeper.

4. Apparatus in accordance with claim 3, wherein the lift means includes a platfonn and guides therefor and the gauging means also includes a platform and guides therefor, the catch members being, respectively, a portion of the gauging platform that overlaps a portion of the lift platform and the indexing rod depending from fixed securement to the gauging platform.

5. Apparatus in accordance with claim 4, wherein the actuating means include fluid-actuated, piston and cylinder power devices for the lift means and the brake, respectively, both being vertically mounted in fixed positions above the respective devices actuated thereby, with depending piston rods connected with said devices, the brake being of grab type having means for binding against the piston rod of that power device which actuates the lift means when such binding means is forced downwardly by the power device that actuates the brake.

6. Apparatus in accordance with claim 5, wherein the actuating means further include fluid-actuated power devices for the gauging means and the latchbolt, respectively, and wherein there is additionally included a fluidic control system for controlling operation of the several power devices.

7. Apparatus in accordance with claim 6, including a liquidcooled housing within which the specified components, including the fluidic control system, are protectively encased against the head from molten material being cast, both the indexing rod and the sensing means extending through said housing to perform their respective functions.

8. Apparatus in accordance with claim I, wherein the actuating means are fluid powered and the sensing means are electrical, and wherein there are additionally included a fluidic control system for the actuating means and an electrical control system governing the operation of the fluidic control system. 

2. Apparatus in accordance with claim 1, wherein the gauging means includes a rigid, depending, indexing rod and carries a latch keeper that forms part of the latch means, the sensing means being flush with the lower end of said indexing rod; and wherein the latch means also includes a latchbolt carried by the lift means and adapted to be thrown into and to be withdrawn from said keeper.
 3. Apparatus in accordance with claim 2, wherein the latch means includes abutment catch members on the lift means and the gauging means, respectively, for mutual engagement to raise the sensing means above mold height independently of the latchbolt and keeper.
 4. Apparatus in accordance with claim 3, wherein the lift means includes a platform and guides therefor and the gauging means also includes a platform and guides therefor, the catch members being, respectively, a portion of the gauging platform that overlaps a portion of the lift platform and the indexing rod depending from fixed securement to the gauging platform.
 5. Apparatus in accordance with claim 4, wherein the actuating means include fluid-actuated, piston and cylinder power devices for the lift means and the brake, respectively, both being vertically mounted in fixed positions above the respective devices actuated thereby, with depending piston rods connected with said devices, the brake being of grab type having means for binding against the piston rod of that power device which actuates the lift means when such binding means is forced downwardly by the power device that actuates the brake.
 6. Apparatus in accordance with claim 5, wherein the actuating means further include fluid-actuated power devices for the gauging means and the latchbolt, respectively, and wherein there is additionally included a fluidic control system for controlling operation of the several power devices.
 7. Apparatus in accordance with claim 6, including a liquid-cooled housing within which the specified components, including the fluidic control system, are protectively encased against the head from molten material being cast, both the indexing rod and the sensing means extending through said housing to perform their respective functions.
 8. Apparatus in accordance with claim 1, wherein the actuating means are fluid powered and the sensing means are electrical, and wherein there are additionally included a fluidic control system for the actuating means and an electrical control system governing the operation of the fluidic control system. 